Upholstered furniture method, apparatus and structure



J1me 1966 D. T. ARMSTRONG 3,256,041

UPI-IOLSTERED FURNITURE METHOD, APPARATUS AND STRUCTURE Filed Feb. 20, 1964 5 Sheets-Sheet 1 IS F l3 FIG.3.

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m 2 L 2 S a 9 E 2 L: J :0 w 9kg 3 r INVENTOR DAVID T. ARMSTRONG ATTORNEY June 14, 1966 ARMSTRONG 3,256,041

UP'HOLSTERED FURNITURE METHOD, APPARATUS AND STRUCTURE Filed Feb. 20, 1964 5 Sheets-Sheet 2 I NVENTOR.

DAVID T. ARMSTRONG ATTORNEY June 14, 1966 ARMSTRONG 3,256,041

UPHOLSTERED FURNITURE METHOD, APPARATUS AND STRUCTURE 5 Sheets-Sheet 5 Filed Feb. 20, 1964 DAVID T. ARMSTRONG ATTORNEY I holstered frame srtuctures.

3,256,041 UPHOLSTERED FURNITURE METHOD, APPARATUS AND STRUCTURE David T. Armstrong, Canton, Miss. Filed Feb. 20, 1964, Ser. No. 346,308

- 2 Claims. (Cl. 297448) This invention relates to a method of and apparatus for making upholstered furniture and the furniture formed thereby. More particularly, this invention relates to a method and apparatus for forming arm structures, wing structures, and other parts for upholstered chairs, couches and the like.

In conventional upholstered furniture arm and frame construction, heavy frame members are first assembled and fastened together as by doweling, nailing or the like, in order to support the frame. In most instances it is necessary to saw or shape curves or other intricate designs on top arm frame members. In order to upholster conventional frame construction, it is necessary to add coverings to the frame, such as chipboard, burlap, etc., in order to support the padding and/ or upholstering fabric which is stretched over the chipboard, burlap, etc., and tacked or stapled to tack strips positioned at various points in the frame. Because of the high cost of labor 'and material and the growing competition in the upholstering furniture manufacturing business, it has become imperative that new methods and techniques of manufacturing upholstered furniture be devised in order to reduce the number of parts, fasteners and material in the furniture and to also reduce the cost of labor required for assembly.

Accordingly, it is an object of this invention to provide a method of and apparatus for constructing upholstered furniture whereby the need for doweling or nailing, or otherwise fastening interior frame members is eliminated.

Another object of this invention is to provide a method of and apparatus for constructing upholstered furniture frames, wherein the use of an inner covering such as chipboard or burlap or the like for supporting the outer upholstering fabric is eliminated.

A further object of this invention is to provide a methodof and apparatus for constructing upholstered furniture wherein exterior skin members of masonite, plywood or other laminated material is directly glued or stapled to interior frame members, thereby not only reducingthe number of interior frame members required, but also permitting the interior frame members to 'be directly glued or stapled to the exterior skin.

Another object of this invention is to provide a method of and apparatus for constructing upholstered furniture utilizing exterior skin directly attached to interior frame members, thereby permitting exterior upholstering fabric to be tacked, stapled, glued or otherwise fastened directly to the exterior skin and thus eliminating the need for extra interior frame members and tack strips normally required to provide' stapling support in convenitonal up- Still another object of this invention is to provide a method of and apparatus for constructing upholstered furniture utilizing exterior skin wherein a stronger struc- 'and then directly glued to exterior skins on opposite sides.

These and many other objects may be achieved in accordance with the method of this invention which in general may include the steps of positioning the interior members comprising the frame in a suitable form, applying glue or other adhesive to an edge of the parts posi- United States Patent tioned in the form; cutting an exterior skin member to the desired profile corresponding to the interior frame; positioning said exterior skin on the glued edges of said interior frame members; placing a stencil corresponding to the position of the interior frame members of said frame on said exterior skin; and attaching said exterior skin to said interior frame members by means of suitable fasteners utilizing said stencil. The skin on the opposite side of the frame is similarly secured to the frame by turning the assembly over; applying glue to the exposed edges of the interior frame members; placing a second skin cut to the desired profile on said glued exterior edges; placing a similar stencil on said second skin; and fastening said second skin to said interior frame as by stapling or nailing, utilizing said stencil placed thereon.

Apparatus for practicing the method of skin construction in upholstered furniture may in general include a first form comprising upright stops arranged in a determined configuration to form an interior profile, said first form being of suficient depth to, receive said interior members; a stencil having cut-out portions corresponding to the configuration formed by said interior frame members when positioned in said first form hingedly secured to said first form; a second form corresponding to the configuration of the interior frame members as positioned in said first form, positioned adjacent said first form; and a second stencil similar in configuration to said first stencil, pivotally secured to said second form.

' An upholstered furniture structure in accordance with the principles of this invention may include. a plurality of interior members arrangedin a desired configuration to form a determined profile; an exterior skin cut to said determined profile glued to said interior members; and an upholstering fabric directly secured to said exterior skin.

These and many other objects and advantages of this invention will become more readily apparent from the following detailed description when read in view of the appended drawings wherein:

FIGURE 1 is a plan view of forms and stencils in accordance with the principles of this invention;

FIGURE 2 is a sectional view taken along the lines 22 of FIGURE 1, illustrating the interior of the forms in greater detail;

FIGURE 3 is an end view of the form illustrating the manner in which the stencils are pivotally secured to the form;

FIGURE 4 illustrates the heavy framing construction of conventional upholstered frame construction;

FIGURE 5 illustrates a chair-arm construction in accordance with the skin-type construction of this invention;

FIGURE '6 further illustrates the conventional heavy frame construction in upholstered wing-back type of chair; and 7 FIGURE 7 illustrates a wing-back chair constructed in accordance with the skin-type structure of this invention.

Referring now to the drawings, FIGURES 1 through 3 illustrate a preferred embodiment of an apparatus for practicing this invention and which in general includes adjacent molds or forms 11 and 12 of wood, metal, plastic of other suitable material, to which are attached as by means of hinges 13 suitable stencils 14 and 16, respectively. In the arrangement shown, the forms 11 and 12 are arranged for the assembly of upholstered chair arms although, as will become apparent, forms for producing any portion of an upholstered chair, sofa, couch or the like may be provided utilizing the principles of this invention.

The form 11 is provided with a suitable cavity 17 of sufficient depth to receive stop members 18 positioned on edge and arranged within the cavity 17 in the desired configuration. As noted in this instance the stops 18 are arranged to form a chair arm. Frame members 19 of the chair arm are then positioned on edge within the cavity between the stops 18. The interior frame members 19 may be arranged to engage one another so as to provide a continuous exterior or certain of the frame members 19 may be foreshortened and spaced from adjacent frame members as designated by the reference numeral 21. The number, size and shape of the interior frame members are of course variable and determine the configuration and profile of the structure to be formed.

The form 12 is provided with a cavity 22 of the same depth as the cavity 17 and is positioned adjacent the form 11. No stop members 18 are utilized in the cavity 22 in the form 12 and the cavity 22 conforms in configuration to the outside members of the interior frame members 19 as arranged within the form 11.

The stencils 14 and 16 may be formed of sheet metal plastic, plywood or the like, and are pivotally attached to the forms 11 and 12, respectively, by hinges 15. Both stencils include cut-out portions 23 corresponding in position to the location of the interior frame members 19 and 21 as positioned between the stops 18 in the form 11. The cut-out portions 23 of the stencils 14 and 16 form a pattern that corresponds in configuration to the exterior of the armchair structure as determined by the interior frame members 19.

In practice, the construction of a typical skin frame using a form and stencil in accordance with this invention is as follows. The interior frame parts 19 are placed on edge in the form 11 between the stops 18 and then glue or other suitable adhesive is applied to the upper exposed edges of the members 19. A sheet of Masonite, plywood or other similar hardboard or lamination which has been cut to exact outline of the desired overall frame is then laid over the form and pressed onto the glued edges of the members 19. The stencil 14 is then swung into position and laid directly on the exterior skin now glued to the interior frame members. As the cut-out portions 23 of the stencil 14 correspond in position to the location of the interior frame members 19 under the skin, the skin is then readily stapled or nailed or otherwise fastened directly to the interior frame members 19 by driving nails or staples into the skim through the cut-out portions 23 in the stencil 14. Having nailed or stapled at spaced intervals completely around the configuration of the interior frame within the cut-out portions 23, the stencil 14 is then raised and the entire frame with one side having a skin attached thereto is turned end-for-end and upside down and placed in the adjacent form 22. As the first skin supports the interior frame members 19 in the desired position, no stops 18 are required in the cavity 22 in the form 12. The exposed upper edges of the interior frame members 19 are then covered with glue or suitable adhesive and a second skin placed over them in the form 12. The stencil 16 is then swung into position over the second skin which is stapled or nailed, or otherwise fastened to the interior frame members 19. The stencil .16 is then raised and the completed chair arm section,

both sides having been skinned, removed from the form 12. The desired upholstering fabric may then be tacked or stapled directly to the exterior skin of the chair arm, thereby eliminating the use of chipboard or burlap as in conventional upholstered construction. There is no need to stretch any other supporting material over the frame at a later stage of the upholstery operation, and the chair arm may now be directly assembled into the completed chair.

Thus the invention provides a method of and apparatus for constructing upholstered furniture that provides numerous advantages and features over the conventional upholstered furniture construction. An important feature of the skin frame construction of this invention is that it eliminates the need for doweling, nailing or otherwise fastening interior frame members to each other, as it is merely necessary to position interior frame members 19 within the form 11. Both exterior skins may then be glued and stapled directly to the interior frame members to provide an exceptionally strong structure requiring a minimum use of interior parts and fasteners.

Interior frame pieces can be located within the skins wherever mechanisms (such as for recliners, sofa beds, etc.) are to be mounted and can be so arranged as to provide direct transmission of the load through said interior members to main peripheral members and so to the floor. (Part 29 in FIG. 5 is such a member.)

Basically, the strength and rigidity of this type construc tion is obtained from the skin itself. The interior wood members to which the skin is fastened prevent the skin from buckling as it would due to a columnar effect if a load were applied in a vertical direction to an unsupported skin. The skin also eliminates the need for diagonal bracing (i.e., corner blocks) between interior frame members because of the inherent strength and rigidity of the skin in the plane of the skin.

Further, the necessity of sawing or shaping curves or other intricate designs on top arm frame members is reduced or eliminated as short scrap pieces can be utilized to form the interior frame and to approximate the desired curves with little loss of strength by using the exterior skin. In addition, the use of exterior skins provides more accuracy and exactness of profile of the finished chair arm as the inaccuracies introduced by variable tolerances between the multiple interfitting pieces of conventional frame construction is eliminated.

Another important saving is the elimination of extra interior frame members such as tack strips for providing stapling support, as in the conventional construction, because in utilizing the skin construction techniques the exterior skin alone holds the necessary staples. And, of course, by eliminating the number of parts required, the number of fasteners to be installed, the manufacturing time and thus cost is decreased. In accordance with the invention, the interior frame parts are simply positioned within the form, spread with glue and the exterior skin stapled down on the interior frame members. This provides a great savings in manufacturing costs.

A primary advantage of upholstered furniture constructed in accordance with the principles of this invention is that the size and number of interior frame members are greatly reduced and the use of dowels, screws and other fasteners for securing the interior frame members together is eliminated. This results in a great savings. A conventional upholstered chair arm frame structure is illustrated in FIGURE 4, while a similarchair arm construction in accordance with the principles of this invention, is illustrated in FIGURE 5. Having formed the chair arm construction of FIGURE 4 by fastening the various frame members together as by screws 24, it is then necessary to staple or tack a chipboard covering or burlap 25 to the frame in order to support the upholstering fabric 25 which is stretched over the frame.

It also should be noted that the upper curved rail of the chair arm construction as shown in FIGURE 4 is formed of one solid piece that has been sawed or otherwise shaped to the desired curvature. Note also in FIG- URE 4, the use of a second continuous and heavy interior rail 27 in the conventional structure shown in FIG- URE 4 and the corner Wedges or braces 20, which are necessary to provide a strong supporting frame.

Referring to FIGURE 5, the advantages of the skin construction technique in accordance with this invention become readily apparent when compared to the conventional practice as illustrated in FIGURE 4. Because of the great strength added by the exterior skin 28, the requirement of a single continuous interior rail 27, as in ,FIGURE 4, is eliminated and a shortened rail 29 is all that is required. Of particular importance is the fact that by utilizing the skin construction technique, the neces sity of using a single curved upper rail in a chair arm is eliminated, that is, it is possible using the skin construction to utilize shortened scraps of material 31 positioned so as to approximate the desired curvature of the finished arm. The exterior skins are cut to the desired profile and the sections 31 are glued and stapled directly to the exterior skin. This construction not only provides a more exact profile and eliminates the use of fasteners but provides greater strength than the conventional chair arm construction as shown in FIGURE 4.

Referring now to FIGURE 6, a conventional upholstered chair having a wingback is illustrated, while FIG- URE 7 illustrates a similar wingba-ck chair in accordance with the skin-type construction of this invention. As already stated, it is necessary using conventional uphol stered furniture assembly techniques that all of the heavy interior frame members be fastened together as by doweling or by means of screws or other suitable fasteners and it should be further noted that in general, exceptionally heavy, wide, upper and lower chair rails 36 and 37 must be used in order to provide strength and also the necessary tacking surface for stapling or tacking the numerous coverings of chipboard and burlap 40 prior to stretching the upholstering fabric 40' over the frame. In addition, a third heavy interior rail 38 is required in conventional structures. In order to form the wingback itself, exceptionally heavy form members 39 are necessary again to provide the excessively large tacking and stapling surface required in order to apply the numerous coverings or burlap 40 prior to stretching the exterior upholstering fabric 40' over the Wingback frame.

The advantages of the skin-type construction in accordance with this invention in assembly wingback chairs are clearly demonstrated by FIGURE 7. As already described the use of exterior skins on both sides of the frame not only provides exceptional strength, but it eliminates the use of numerous interior parts and fasteners because interior fasteners are not required and because the upholstering fabric can be stapled or nailed directly to the exterior skin, thus eliminating the requirement for excessive interior stapling surfaces. As shown in FIGURE 7, the rails36 and 38 of FIGURE 6 are completely eliminated and the bottom rail 41 of the chair illustrated in FIG- URE 7 is greatly reduced in size. The use of exterior skins 42 in the arm frame and wings of the chair as illustrated in FIGURE 7 'is of great advantage not only because it greatly reduces the size of the interior members 43 forming the wing compared to the members 39 of FIGURE 6, but because it greatly reduces the time for assembly. The tedious time-consuming operations of stretching one or more layers of burlap over the curved wing surfaces is eliminated and a much stronger wing is provided. Further, the wing sections themselves can be preformed if desired. Having completed the skin construction, the exterior upholstering fabric 44 may then be directly stapled or tacked to the exterior skins 42 of the wings and the chair arms.

Although a preferred embodiment of the invention has been described in detail, numerous modifications and changes can be made within the principles of the invention which is to be limited only by the scope of the appended claims.

What is claimed is: 1. An upholstered chair arm structure comprising: a lower chair rail; front and rear uprights secured to said lower chair rail; a plurality of short-spaced pieces forming an upper chair rail, said short pieces being positioned so as to approximate a determined curve;

exterior and opposing skins secured on opposite sides to said lower and upper rails and said front and rear uprights, said exterior opposing skins locking said lower and upper rail and said front and rear uprights in position; and

an exterior upholstering fabric stretched over and attached directly to said exterior opposing skins.

2. A chair arm structure comprising: a plurality of adjoining interior frame members including a lower chair arm rail member, front and rear upright members, and an upper chair arm rail member arranged in a determined position to provide a frame structure of a desired configuration; and exterior and opposing skins corresponding to said determined configuration of said interior framework secured to opposite sides of said lower and upper rails and said front and rear uprights, said exterior opposing skins locking said lower and upper rail members and said front and rear upright members in position to strengthen said structure in the plane of said exterior opposing skins, said interior members strengthening said chair arm structure in a plane perpendicular to the plane of said exterior opposing skins.

References Cited by the Examiner UNITED STATES PATENTS 473,204 4/1892 Beasley 2991.8 1,590,135 6/1926 Upham 2991.1 1,930,574 10/1933 Wolf 2991.8 1,940,636 12/ 1933 .Stubnitz 29-91.1 2,612,213 9/1952 Bott 297218 2,660,228 11/1953 Reinhold 297452 2,913,041 11/1959 Mathison 297452 3,070,402 12/ 1962 .Stanton 297421 3,107,944 10/ 1963 Baermann 297452 3,120,407 2/ 1964 Propst 297457 FOREIGN PATENTS 881,875 11/1959 Great Britain.

926,720 5/ 1963 Great Britain.

FRANK B. SHERRY, Primary Examiner.

THOMAS H. EAGER, Examiner. I

C. A. NUNBERG, Assistant Examiner. 

1. AN UPHOLSTERED CHAIR ARM STRUCTURE COMPRISING: A LOWER CHAIR RAIL; FRONT AND REAR UPRIGHTS SECURED TO SAID LOWER CHAIR RAIL; A PLURALITY OF SHORT-PACED PIECES FORMING AN UPPER CHAIR RAILS, SAID SHORT PIECES BEING POSITIONED SO AS TO APPROXIMATE A DETERMINED CURVE; EXTERIOR AND OPPOSING SKINS SECURED ON OPPOSITE SIDES TO SAID LOWER AND UPPER RAILS AND SAID FRONT AND REAR UPRIGHTS, SAID EXTERIOR OPPOSING SKINS LOCKING SAID LOWER AND UPPER RAIL AND SAID FRONT AND REAR UPRIGHTS IN POSITION; AND AN EXTERIOR UPHOLSTERING FABRIC STRETCHED OVER AND ATTACHED DIRECTLY TO SAID EXTERIOR OPPOSING SKINS. 